Multiple axis positioner

ABSTRACT

An embodiment of a multiple axis positioner comprises a main headstock that has a main hollow bore. A main indexing table is attached to the main headstock. The main indexing table has a through-hole near the its center. The through-hole aligns or is substantially coaxial with the main hollow bore of the main headstock. The embodiment of the multiple axis positioner further includes at least three minor headstocks mounted to the main indexing table. The at least three minor headstocks have minor hollow bores.

FIELD OF INVENTION

The present application relates to a positioner for an arc weldingsystem. More particularly, the present application relates to a multipleaxis positioner.

BACKGROUND

A workpiece positioner requires an operator to load and unload theworkpiece on to the positioner or on to a fixture attached to thepositioner. In some cases, a workpiece may require more than oneoperation, thus requiring multiple instances of loading and unloadingthe workpiece. Some operations may require various cables, hoses, and soon to be brought in the direction of the workpiece.

SUMMARY

An embodiment of a multiple axis positioner comprises a main headstockthat has a main hollow bore. A main indexing table is attached to themain headstock. The main indexing table has a through-hole near the itscenter. The through-hole aligns or is substantially coaxial with themain hollow bore of the main headstock. The embodiment of the multipleaxis positioner further includes at least three minor headstocks mountedto the main indexing table. The at least three minor headstocks haveminor hollow bores.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, structures are illustrated that, togetherwith the detailed description provided below, describe exemplaryembodiments of the claimed invention.

In the drawings and description that follows, like elements areidentified with the same reference numerals. The drawings are not toscale and the proportion of certain elements may be exaggerated for thepurpose of illustration.

FIG. 1 illustrates a perspective view of one embodiment of a multipleaxis positioner.

FIG. 2 illustrates a top view of one embodiment of a multiple axispositioner.

FIG. 3 illustrates a perspective view of the one embodiment of themultiple axis positioner including a top shield.

FIGS. 4 illustrates a perspective view of one embodiment of a roboticwelding station including one embodiment of a multiple axis positioner.

FIGS. 5 illustrates a top view of the one embodiment of the roboticwelding station including the multiple axis positioner.

DETAILED DESCRIPTION

FIGS. 1 and 2, illustrate a perspective view and a top view,respectively, of an embodiment of a multiple axis positioner 100. In theillustrated embodiment, the positioner 100 is a multistation apparatusthat may be used as a holder for workpieces during various operations(e.g. welding, hard facing, and so on).

In the illustrated embodiment, the positioner 100 includes a main orprimary rotary table 10. Primary rotary table 10 includes a surface thatforms a through-hole 20 located at the center of the rotary table 10.The positioner 100 may also include bases 30 a-c that are operativelyconnected to the rotary table 10. The minor or secondary rotary tables40 a-c are operatively connected to the bases 30 a-c. In the illustratedembodiment, each of the minor rotary tables 40 a-c includes a centersurface forming a through hole 50 a-c located substantially at thecenter of each minor rotary table 40 a-c. Although three minor rotarytables 40 a-c are shown, the positioner 100 may include more or lessthan three minor rotary tables.

In the illustrated embodiment, the positioner 100 includes a primarybase 60. The primary base 60 is configured to support the positioner 100via a connection to a wall. In alternative embodiments, the base 10 maysupport the positioner 100 via a connection to a floor, workstationwalls, a ceiling, and so on. In the embodiment, the primary rotary table10 is operatively connected to the primary base 60.

In the illustrated embodiment, the positioner 100 includes a primarymotor 70 operatively connected to the primary rotary table 10. Theprimary motor 70 rotates the primary rotary table 10. As best seen inFIG. 2, the primary motor 70 is located at an off-center position inreference to the primary through-hole 20 such that the primarythrough-hole 20 is substantially unobstructed by the primary motor 70.

In the illustrated embodiment, the positioner 100 also includes threesecondary motors 80 a-c. Each of the secondary motors 80 a-c isoperatively connected to one of the minor rotary tables 40 a-c. Each ofthe secondary motors 80 a-c rotates one of the minor rotary tables 40a-c. Each of the secondary motors 80 a-c is located at an off-centerposition in reference to its associated secondary through-hole 50 a-csuch that the secondary through-holes 50 a-c are unobstructed by thesecondary motors 80 a-c. The location of the secondary motors 80 a-c inreference to the secondary through-holes 50 a-c may be best appreciatedlooking at the location of secondary motor 80 b in reference tosecondary through-hole 50 b in FIG. 1.

In one embodiment (not shown), cables, hoses, ground cables, and so onmay be routed through the primary and secondary through-holes. Suchcables, hoses, or ground cables may be connected to a fixture orworkpiece, or used in operations performed on the workpiece.

In reference to FIG. 3, the positioner 100 may include a protectiveenclosure or top shield 90 operatively connected to the primary rotarytable 10. The top shield 90 may provide protection to cables, hoses,instrumentation, and so on that may be routed through the primarythrough-hole 20 and the secondary through-holes 50 a-c.

FIGS. 4 and 5, illustrate a perspective view and a top view,respectively, of an embodiment of a robotic welding station 400including a multiple axis positioner 405. In the illustrated embodiment,the positioner 405 includes a main hollow bore headstock 410 and a mainindexing table 420. The main indexing table 420 includes a centersurface forming a main through-hole (not shown) on the main indexingtable 420. The main through-hole 420 aligns or is substantially coaxialwith the hollow bore of the main hollow bore headstock 410. The mainhollow bore headstock 410 includes a main motor 430. In this embodiment,the main motor 430 is positioned such that it does not obstruct the mainthrough-hole of the main indexing table 420 or the hollow bore of themain hollow bore headstock 410.

In the illustrated embodiment, the positioner 405 also includes threeminor hollow bore headstocks 440 a-c. Each of the minor hollow boreheadstocks 440 a-c is operatively connected to the main indexing table420. The minor hollow bore headstocks 440 a-c include minor motors (notshown). The minor motors are located at an off-center position inreference to the minor hollow bore headstocks' hollow bores such thatthe hollow bores are substantially unobstructed by the minor motors. Inthe illustrated embodiment, the three minor hollow bore headstocks 440a-c are located at substantially the same distance from each other onthe main indexing table 420 such that the central axes of the headstocks440 a-c are located at substantially 120 degree increments around themain indexing table 420. Alternative embodiments may include more orless than three minor headstocks, and minor headstocks located atpositions other than 120 degree increments.

In an alternative embodiment (not shown), the main hollow bore headstock410 includes a main motor that has a hollow shaft. In such anembodiment, the main motor's hollow shaft is substantially aligned orsubstantially coaxial with the main through-hole. The main through-holeis unobstructed although the main motor is centered with respect to themain through-hole.

In another alternative embodiment (not shown), the minor hollow boreheadstocks 440 a-c include minor motors that have hollow shafts. In suchan embodiment, the minor motors' hollow shafts are substantially alignedor substantially coaxial with the respective hollow bores of the minorhollow bore headstocks 440 a-c. The hollow bores of the minor hollowbore headstocks 440 a-c are unobstructed even though the minor motorsare centered with respect to the hollow bores.

In the illustrated embodiment, the robotic welding station 400 alsoincludes robot arms 450 a-b carrying welding torches 455 a-b. The robotarms 450 a-b are mounted to platforms 460 a-b. The robotic weldingstation 400 also includes shields 470 a-c arranged between threeworkstations WS0, WS1, and WS2 for shielding and protecting areasoutside each workstation during performance of operations such aswelding, hard facing, and so on.

In the illustrated embodiment, the minor headstocks 440 a-c carryworkpieces 480 a-c. Individual components of the workpieces 480 a-c areloaded on to fixtures (not shown) at an operator's workstation WS0 priorto welding and are held in place by holding devices (not shown). Robotarm 450 a may perform a first operation on the workpieces 480 a-c inworkstation WS1, and robot arm 450 b may perform a second operation onthe workpieces 480 a-c in workstation WS2. In the embodiment, theindexing table 420 rotates in a counter-clockwise direction to index theworkpieces 480 a-c from workstation WS0 to workstation WS1 toworkstation WS2. Alternatively, indexing table 420 may rotate in aclockwise direction to index the workpieces 480 a-c from workstation WS0to workstation WS2 to workstation WS1.

FIGS. 4 and 5 illustrate the robotic welding station after all of theworkpieces 480 a-c have been loaded on to the positioner 405. Theprocess may begin by an operator loading a first workpiece 480 a to afirst fixture (not shown) located in the operator's work station WS0.Once the workpiece 480 a has been loaded, the indexing table 420 indexesthe first fixture 120 degrees counter-clockwise to locate the firstworkpiece 480 a in the first workstation WS1 for robot arm 450 a toperform a first operation on the first workpiece 480 a. In analternative embodiment, the fixture may be indexed clockwise instead.While the robot arm 450 a performs a first operation on the firstworkpiece 480 a, the operator may load a second workpiece 480 b to asecond fixture located in the operator workstation WS0.

Once the robot arm 450 a has completed the first operation on the firstworkpiece 480 a and the operator has loaded the second workpiece 480 b,the indexing table 420 indexes the first fixture and the second fixture120 degrees counter-clockwise to locate the first workpiece 480 a in thesecond work station WS2 and the second workpiece 480 b in the first workstation WS1. While the robot arm 450 b performs a second operation onthe first workpiece 480 a and the robot arm 450 a performs the firstoperation on the second workpiece 480 b, the operator may load a thirdworkpiece 480 c to a third fixture located in the operator workstationWS0. This is the configuration shown in FIGS. 4 and 5.

Once robot arm 450 b has completed the second operation on the firstworkpiece 480 a and robot arm 450 a has completed the first operation onthe second workpiece 480 b and the operator has loaded the thirdworkpiece 480 c, the indexing table indexes the first fixture, thesecond fixture, and the third fixture 240 degrees clockwise to locatethe first workpiece 480 a in the operator station WS0, the secondworkpiece 480 b in the second work station WS2, and the third workpiece480 c in the first work station WS1. While the robot arm 450 b performsthe second operation on the second workpiece 480 b and the robot arm 450a performs the first operation on the third workpiece 480 c, theoperator may unload the first workpiece 480 a from the first fixturelocated in the operator workstation WS0. The operator may continue thiscycle until all workpieces have been completed.

In one embodiment, the first operation is a welding operation while thesecond operation is a hard facing operation. In an alternativeembodiment, the first operation is a welding operation while the secondoperation is a non-welding operation. Various other operations may beperformed in conjunction with the disclosed multiple axis positioner.

To the extent that the term “includes” or “including” is used in thespecification or the claims, it is intended to be inclusive in a mannersimilar to the term “comprising” as that term is interpreted whenemployed as a transitional word in a claim. Furthermore, to the extentthat the term “or” is employed (e.g., A or B) it is intended to mean “Aor B or both.” When the applicants intend to indicate “only A or B butnot both” then the term “only A or B but not both” will be employed.Thus, use of the term “or” herein is the inclusive, and not theexclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage624 (2d. Ed. 1995).

To the extent that the terms “in” or “into” are used in thespecification or the claims, it is intended to additionally mean “on” or“onto.” Furthermore, to the extent the term “connect” is used in thespecification or claims, it is intended to mean not only “directlyconnected to,” but also “indirectly connected to” such as connectedthrough another component or components. An “operable connection,” or aconnection by which entities are “operably connected,” is one by whichthe operably connected entities or the operable connection perform itsintended purpose. For example, two entities may be operably connected toeach other directly or through one or more intermediate entities.

While example systems, methods, and so on, have been illustrated bydescribing examples, and while the examples have been described inconsiderable detail, it is not the intention of the applicants torestrict or in any way limit the scope of the appended claims to suchdetail. It is, of course, not possible to describe every conceivablecombination of components or methodologies for purposes of describingthe systems, methods, and so on, described herein. Additional advantagesand modifications will readily appear to those skilled in the art.Therefore, the invention is not limited to the specific details, therepresentative apparatus, and illustrative examples shown and described.Thus, this application is intended to embrace alterations,modifications, and variations that fall within the scope of the appendedclaims. Furthermore, the preceding description is not meant to limit thescope of the invention. Rather, the scope of the invention is to bedetermined by the appended claims and their equivalents.

1. A multistation workpiece holder apparatus comprising: at least oneprimary base; a primary rotary table operatively connected to the atleast one primary base, where the primary rotary table includes aprimary center surface defining a primary through-hole locatedsubstantially at the center of the primary rotary table; a plurality ofsecondary bases, where each of the secondary bases is operativelyconnected to the primary rotary table; and a plurality of secondaryrotary tables, including at least a first secondary rotary table and asecond secondary rotary table where the first secondary rotary tableincludes a first secondary center surface defining a first secondarythrough-hole located substantially at the center of the first secondaryrotary table, where the first secondary rotary table is operativelyconnected to a first secondary base, where the second secondary rotarytable includes a second secondary center surface defining a secondsecondary through-hole located substantially at the center of the secondsecondary rotary table, and where the second secondary rotary table isoperatively connected to a second secondary base.
 2. The multistationworkpiece holder apparatus of claim 1, further comprising: a primarymotor operatively connected to the primary rotary table and configuredto rotate the primary rotary table about a primary axis substantiallycentral to the primary rotary table.
 3. The multistation workpieceholder apparatus of claim 2, where the primary motor is disposed suchthat the primary through-hole is substantially unobstructed by theprimary motor.
 4. The multistation workpiece holder apparatus of claim3, further comprising: a plurality of secondary motors, where a firstsecondary motor from the plurality of secondary motors is operativelyconnected to the first secondary rotary table and configured to rotatethe first secondary rotary table about a first secondary axis, and wherea second secondary motor from the plurality of secondary motors isoperatively connected to the second secondary rotary table andconfigured to rotate the second secondary rotary table about a secondsecondary axis.
 5. The multistation workpiece holder apparatus of claim4, where the first secondary motor is disposed such that the firstsecondary through-hole is substantially unobstructed by the firstsecondary motor, and where the second secondary motor is disposed suchthat the second secondary through-hole is substantially unobstructed bythe second secondary motor.
 6. The multistation workpiece holderapparatus of claim 5, where the plurality of secondary rotary tablesfurther includes a third secondary rotary table having a third secondarycenter surface defining a third secondary through-hole locatedsubstantially at the center of the third secondary rotary table, wherethe third secondary rotary table is operatively connected to a thirdsecondary base, where a third secondary motor is operatively connectedto the third secondary rotary table and configured to rotate the thirdsecondary rotary table about a third secondary axis, and where the thirdsecondary motor is disposed such that the third secondary through-holeis substantially unobstructed by the third secondary motor.
 7. Themultistation workpiece holder apparatus of claim 6, further comprisingat least three station shields operatively connected to the primaryrotary table, where a first station shield is located between the firstsecondary base and the second secondary base, a second station shield islocated between the second secondary base and the third secondary baseand a third station shield is located between the third secondary baseand the first secondary base.
 8. The multistation workpiece holderapparatus of claim 6, further comprising a top shield operativelyconnected to the primary rotary table.
 9. The multistation workpieceholder apparatus of claim 1, further comprising: a plurality ofsecondary motors, where a first secondary motor from the plurality ofsecondary motors is operatively connected to the first secondary rotarytable and configured to rotate the first secondary rotary table about afirst secondary axis, and where a second secondary motor from theplurality of secondary motors is operatively connected to the secondsecondary rotary table and configured to rotate the second secondaryrotary table about a second secondary axis.
 10. The multistationworkpiece holder apparatus of claim 9, where the first secondary motoris disposed such that the first secondary through-hole is substantiallyunobstructed by the first secondary motor, and where the secondsecondary motor is disposed such that the second secondary through-holeis substantially unobstructed by the second secondary motor.
 11. Themultistation workpiece holder apparatus of claim 10, where a thirdsecondary rotary table from the plurality of secondary rotary tablesincludes a third secondary center surface defining a third secondarythrough-hole located substantially at the center of the third secondaryrotary table, where the third secondary rotary table from the pluralityof secondary rotary tables is operatively connected to a third secondarybase from the plurality of secondary bases, where a third secondarymotor from the plurality of secondary motors is operatively connected tothe third secondary rotary table and configured to rotate the thirdsecondary rotary table about a third secondary axis, and where the thirdsecondary motor is disposed such that the third secondary through-holeis substantially unobstructed by the third secondary motor.
 12. Arobotic welding positioner comprising: a main headstock having a mainhollow bore and a main indexing table, where the main indexing tableincludes a center surface forming a main through-hole on the mainindexing table, where the main through-hole is substantially coaxialwith the main hollow bore; and at least three minor headstocksoperatively connected to the main indexing table, where the at leastthree minor headstocks have minor hollow bores.
 13. The robotic weldingpositioner of claim 12, where the at least three minor headstocks arelocated equidistantly around the main indexing table.
 14. The roboticwelding positioner of claim 12, further comprising a main motor operablyconnected to the main headstock and configured to rotate the mainindexing table, where the main motor is positioned such that the mainmotor does not obstruct the main through-hole and the main hollow bore.15. The robotic welding positioner of claim 12, further comprising: atleast three minor motors, where a first minor motor is operablyconnected to a first minor headstock from the at least three minorheadstocks and configured to cause the first minor headstock to rotate,where the first minor headstock has a first minor hollow bore and wherethe first minor motor is positioned such that the first minor motor doesnot substantially obstruct the first minor hollow bore, where a secondminor motor is operably connected to a second minor headstock from theat least three minor headstocks and configured to cause the second minorheadstock to rotate, where the second minor headstock has a second minorhollow bore and where the second minor motor is positioned such that thesecond minor motor does not substantially obstruct the second minorhollow bore, where a third minor motor is operably connected to a thirdminor headstock from the at least three minor headstocks and configuredto cause the third minor headstock to rotate, and where the third minorheadstock has a third minor hollow bore and where the third minor motoris positioned such that the third minor motor does not substantiallyobstruct the third minor hollow bore.
 16. The robotic welding positionerof claim 12, further comprising: at least three minor motors, where afirst minor motor is operably connected to a first minor headstock fromthe at least three minor headstocks and configured to cause the firstminor headstock to rotate, where the first minor headstock has a firstminor hollow bore and where the first minor motor has a hollow firstminor shaft substantially aligned with the first minor hollow bore,where a second minor motor is operably connected to a second minorheadstock from the at least three minor headstocks and configured tocause the second minor headstock to rotate, where the second minorheadstock has a second minor hollow bore and where the second minormotor has a hollow second minor shaft substantially aligned with thesecond minor hollow bore, where a third minor motor is operablyconnected to a third minor headstock from the at least three minorheadstocks and configured to cause the third minor headstock to rotate,and where the third minor headstock has a third minor hollow bore andwhere the third minor motor has a hollow third minor shaft substantiallyaligned with the third minor hollow bore.
 17. The robotic weldingpositioner of claim 12, further comprising a main motor operablyconnected to the main headstock and configured to cause the mainindexing table to rotate, where the main motor has a hollow main shaftsubstantially aligned with the main through-hole and the main hollowbore.
 18. The robotic welding positioner of claim 12, further comprisingat least three shields operatively connected to the main headstock,where a first shield from the at least three shields is located betweenthe first minor headstock and the second minor headstock, a secondshield is located between the second minor headstock and the third minorheadstock and a third shield is located between the third minorheadstock and the first minor headstock.
 19. A workpiece positionercomprising: a rotary platform having a top surface and a center surfaceforming a main through-hole; means for holding a plurality ofworkpieces, where the means for holding include minor center surfacesforming minor through-holes, and where the means for holding areoperatively connected to the top surface; and means for rotating therotary platform about an axis of rotation perpendicular to the topsurface, where the means for rotating the rotary platform are locatedsuch that the main through-hole is unobstructed.
 20. The robotic weldingpositioner of claim 19, further comprising: means for rotating the meansfor holding the plurality of workpieces, where the means for rotatingthe means for holding the plurality of workpieces are located such thatthe minor through-holes are unobstructed.